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Posted: 6/13/2026 7:18:34 PM EDT
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I recently considered selling one of my Prototypes (the clone of #11 that still needs work), but realized that it isn't going to sell as an unfinished project. I'm back in the game, and working on a set of Prototype handguards. I drilled the extra holes in the top of the handguard and Bondo'ed up the unnecessary holes on the bottom. I glued the two halves together with heat shields in place. Still need to completely fill the side holes. I think I've figured out a way to make them slip over a delta ring. First, I coated a delta ring in paste wax so epoxy won't stick. I also coated the inside of a Barbasol shaving cream cap with paste wax. I dropped the delta ring into the Barbasol cap and these two pieces became my mold. I filled the space around the delta ring with JB Weld Plastic Weld. This was the result after I removed the Barbasol cap: Then I pressed the delta ring into place on the rear of the handguard with the newly created Plastic Weld collar around it. I used more Plastic Weld to connect the collar to the handguard. This is the result: This should slide as one-piece over the delta ring, then be retained by the front cap. Next step is to finish filling the side holes, then sand the excess Bondo smooth, spray with filler-primer, spray with Hound Brown dip paint, then dip and clearcoat. Whether I sell it or not, I really need to finish this one up. It has been sitting incomplete for years. |
| Very cool. I have a few proto projects i need to start this decade lol |
"History does not long entrust the care of freedom to the weak or the timid"
"A people that values its privileges above its principles soon loses both"
“So Freedom Will Reign” / “SEEK! STRIKE! DESTROY!” / “Led By Love Of Country!”
"A people that values its privileges above its principles soon loses both"
“So Freedom Will Reign” / “SEEK! STRIKE! DESTROY!” / “Led By Love Of Country!”
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Nice work so far! But, why use a Delta ring at all? You don't need it since the handguard will be one-piece, and can only be installed by removing the FSB and end cap. You could have cut out the very back portion of the handguard that goes around the "teeth" of the barrel nut, and have the handguard rest against the face of the nut. The little lugs that fit between the teeth would locate/orient the handguard. The extension could then be made on a cylindrical form that fit over the teeth and blended into the rear of the handguard. |
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Originally Posted By Dex223: Nice work so far! But, why use a Delta ring at all? You don't need it since the handguard will be one-piece, and can only be installed by removing the FSB and end cap. You could have cut out the very back portion of the handguard that goes around the "teeth" of the barrel nut, and have the handguard rest against the face of the nut. The little lugs that fit between the teeth would locate/orient the handguard. The extension could then be made on a cylindrical form that fit over the teeth and blended into the rear of the handguard. You're right about the delta ring being unnecessary, I jumped in without completely planning this one out. I may keep it just to add some rigidity to the back at this point. I sanded the Bondo and hit it with filler-primer today. Will sand it again tomorrow after the filler-primer fully cures. Needs a little touch up in a few spots, then another coat of filler-primer. May be ready to hydro-dip this weekend. The new heat shield holes need to be trimmed a little too. Will use a dremel and a metal cutting bit. |
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Originally Posted By AmateurLuthier: This is the rifle I'm finishing up. https://imageshack.com/i/pnfqwXOWj https://imageshack.com/i/pozHDrxvj I recognize the tag - still haven't used my proto FSB yet, maybe you'll motivate me. |
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Originally Posted By AmateurLuthier: You're right about the delta ring being unnecessary, I jumped in without completely planning this one out. I may keep it just to add some rigidity to the back at this point. I sanded the Bondo and hit it with filler-primer today. Will sand it again tomorrow after the filler-primer fully cures. Needs a little touch up in a few spots, then another coat of filler-primer. May be ready to hydro-dip this weekend. The new heat shield holes need to be trimmed a little too. Will use a dremel and a metal cutting bit. https://imageshack.com/i/pmNBH8wAj Originally Posted By AmateurLuthier: Originally Posted By Dex223: Nice work so far! But, why use a Delta ring at all? You don't need it since the handguard will be one-piece, and can only be installed by removing the FSB and end cap. You could have cut out the very back portion of the handguard that goes around the "teeth" of the barrel nut, and have the handguard rest against the face of the nut. The little lugs that fit between the teeth would locate/orient the handguard. The extension could then be made on a cylindrical form that fit over the teeth and blended into the rear of the handguard. You're right about the delta ring being unnecessary, I jumped in without completely planning this one out. I may keep it just to add some rigidity to the back at this point. I sanded the Bondo and hit it with filler-primer today. Will sand it again tomorrow after the filler-primer fully cures. Needs a little touch up in a few spots, then another coat of filler-primer. May be ready to hydro-dip this weekend. The new heat shield holes need to be trimmed a little too. Will use a dremel and a metal cutting bit. https://imageshack.com/i/pmNBH8wAj You're still doing a great job! It's looking really good so far. I'm especially interested to see the hydro-dip. I think you've said you're going with a weave pattern, but I've been thinking "why doesn't someone offer a hydro-dip that looks like bakelite?" I'd love to do a set of furniture in that. |
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Did a little more work on them, but they don't look any different (spot filling with epoxy). Should do final sand and primer tomorrow. Will dip this weekend if weather permits me to do it on the patio. The hydro film I used for the stock was "Subtle Gold Real Weave" from Big Brain. Big Brain has since gone out of business. I bought a "Gold Real Weave" at another company that I hope is the same thing (none of these companies make their own film). If it looks the same when I dip, I will just dip the handguard. If it is different, I will re-dip the stock too. Will probably also dip the delta ring since the back lip will show. If the delta ring is awkward when I assemble, I will re-work the backend of the handguards as suggested by Dex223. The originals were a carbon fiber weave immersed in epoxy. |
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Good and bad today. Good news. The gold weave hydro dip film I recently purchased is identical to the stuff I used before under a different brand name. Won't have to re-dip the stock. Bad news (kinda'). Two unsuccessful dips this morning. I haven't dipped in years, and I'm re-learning all the stuff that needs a little finesse - like amount of activator and the timing between steps from the point the film touches water. First dip of the day, I didn't apply enough activator or let the film hydrate enough before activation. The dip was a wrinkled gooey mess. Rinsed the part, rubbed all the goo off, rinsed again, dried, and reapplied base paint. Second dip was likely a timing issue - waited too long to dip after activation and dipped too fast when I realized my window was closing, Pin holes. Rinsed and cleaned up again, waiting for the handguard to dry before hitting it with base paint again. Calling it a day after I repaint the handguard. Will resume dipping in the morning. Frustrating because I used to be pretty good at this. |
Just practice your dipping on a vintage ‘59 les paul since it seems you have the capability. Then do your handguards 
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"History does not long entrust the care of freedom to the weak or the timid"
"A people that values its privileges above its principles soon loses both"
“So Freedom Will Reign” / “SEEK! STRIKE! DESTROY!” / “Led By Love Of Country!”
"A people that values its privileges above its principles soon loses both"
“So Freedom Will Reign” / “SEEK! STRIKE! DESTROY!” / “Led By Love Of Country!”
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Originally Posted By AmateurLuthier: https://imageshack.com/i/pmf47rsGj |
An armed society is a polite society.
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Originally Posted By ArmaLite_Aficionado: Just practice your dipping on a vintage ‘59 les paul since it seems you have the capability. Then do your handguards Great idea! If it looks okay, I'll just chop the neck off, hollow it out, and make handguard clamshells out of it. |
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